High-Integrity Flow Control Solutions for Midstream Pipelines and LNG

Discover high-integrity flow control solutions for midstream pipelines and LNG terminals ensuring zero-leakage safety and advanced automation.

The Critical Role of High-Integrity Flow Control in Midstream Operations

Midstream infrastructure serves as the vital link between extraction and market, demanding components that ensure continuous, safe operation. At Delco Valves, we recognize that pipeline integrity relies heavily on the quality of flow control devices installed at pump stations, compressor stations, and storage terminals. As a specialized global manufacturer, we provide the engineering precision and rigorous API-compliant manufacturing necessary to support these mission-critical applications. By adhering to strict international quality standards, we deliver valves that withstand the rigorous demands of transporting oil, natural gas, and NGLs across the globe.

Mitigating Risk Profile: From Gas Transmission to LNG Export

Reducing the risk profile across the energy supply chain requires equipment engineered for extreme conditions. From high-pressure gas transmission to the cryogenic requirements of LNG facilities, equipment failure is not an option. We mitigate operational risks through strict adherence to industry standards and robust material selection, including Carbon Steel, Stainless Steel, and exotic Alloys. Our approach to integrity management involves:

• Comprehensive Standards Compliance: Manufacturing in strict accordance with API 6D (Pipeline Valves) and API 6A (Wellhead Equipment).
• Fire Safe Design: Ensuring valves meet API 607 standards to maintain sealing capability during thermal events.
• High-Pressure Capabilities: Offering pressure classes ranging from ASME 150 to 2500 and API 2000 to 15,000 to handle volatile process conditions.

The “Zero-Leakage” Mandate: Balancing Efficiency with Environmental Safety

In the modern midstream sector, maintaining a leak-tight seal is essential for both operational efficiency and environmental stewardship. High-Integrity Flow Control means deploying valves that provide positive isolation to prevent fugitive emissions and product loss. Our comprehensive line of Trunnion Mounted Ball Valves and Expanding Gate Valves are designed to deliver verifiable shut-off performance. To ensure zero-leakage reliability, we implement:

• Rigorous Factory Testing: Every unit undergoes strict inspection and pressure testing protocols (API 598 / ISO 5208) before shipment.
• Double Block and Bleed (DBB): Critical for liquid pipelines and terminal manifolds to ensure seal integrity.
• Metal-to-Metal Sealing: Utilizing Slab and Expanding Gate designs that provide durable sealing even in abrasive flow conditions.

Process Automation: The Shift to Autonomous Pipeline Management

The industry is rapidly moving toward process automation to enhance safety and response times. Delco Valves supports the transition to autonomous shutdown and remote operation through our integrated actuation solutions. We deliver pre-assembled and calibrated valve automation packages directly from our factory, ensuring seamless compatibility and reducing on-site installation labor. Our capabilities for automated systems include:

• One-Stop Actuation Packages: Fitting valves with pneumatic, electric, or hydraulic actuators for precise remote control.
• Modifications: Tailoring valve stems and ISO mounting pads to accept specific control instrumentation.
• Rapid Turnaround: Leveraging our agile manufacturing capabilities to deliver automated solutions on a fast-track schedule, minimizing downtime during upgrades.

Core Technologies for Gas Transmission & Processing

Compressor Stations: Anti-Surge Control and Isolation Valves

Compressor stations are the heartbeat of the pipeline, and downtime here isn’t an option. We provide robust flow control equipment designed to withstand the heavy vibration and pressure cycling inherent to these facilities. Our Trunnion Mounted Ball Valves are engineered for critical isolation, ensuring a tight seal when you need to take a unit offline for maintenance.

• Reliable Isolation: We supply API 6D ball valves that ensure zero leakage during shut-offs.
• Integrated Solutions: Our engineering team builds custom pneumatic actuation packages that integrate directly into your station’s safety loop.
• Agile Manufacturing: Unlike legacy brands with extended lead times, our flexible production lines allow us to prioritize urgent orders for critical station projects.

Acid Gas & Amine Treating: Handling Corrosive Media with Specialty Alloys

When you are processing sour gas or managing amine units, standard carbon steel simply won’t last. Corrosion is the enemy of integrity management. At Delco Valves, we manufacture valves using high-grade Stainless Steel and exotic alloys specifically chosen to resist chemical attack and hydrogen embrittlement.

• Material Expertise: We offer valves in specialized alloys (Duplex, Inconel, Monel) capable of handling harsh, corrosive media without degrading.
• Diverse Options: From Check Valves to prevent backflow to Plug Valves for tough throttling applications.
• Certified Quality: Every alloy valve undergoes rigorous NDE (Non-Destructive Examination) to ensure it meets NACE MR0175 standards.

Pigging Stations: Large-Bore Trunnion Mounted Ball Valves for Maintenance

Efficient pipeline maintenance relies on the ability to run cleaning and inspection tools without obstruction. Our Large-Bore Trunnion Mounted Ball Valves and Through-Conduit Gate Valves are designed specifically for pigging stations. They feature a full-bore design that provides a perfectly round, unobstructed flow path.

• Piggable Designs: We ensure our valves allow pigs to pass freely, preventing jams and equipment damage.
• Heavy-Duty Construction: Built to handle high-torque operations required during process automation sequences.
• Global Logistics: We have extensive experience shipping large-diameter valves globally, ensuring they arrive at your site ready for immediate installation.

Specialized Cryogenic Solutions for LNG Terminals

We understand that High-Integrity Flow Control for Midstream Pipelines & LNG Terminals demands more than just standard hardware; it requires engineering that withstands the most extreme thermal cycles on earth. At Delco Valves, we leverage our deep expertise in cryogenic applications and rigorous in-house cryogenic testing facilities to ensure our valves meet the volatility of LNG operations head-on.

Cryogenic Liquefaction (-162°C): Preventing Thermal Shock in Critical Valves

Handling natural gas at -162°C introduces severe thermal contraction challenges that can compromise standard seal integrity. Our approach to High-Integrity Flow Control during the liquefaction phase focuses on material stability and precision engineering.

• Material Selection: We utilize Carbon Steel, Stainless Steel, and exotic Alloys capable of maintaining ductility and structural integrity at cryogenic temperatures.
• Design Features: Our cryogenic-ready valves feature extended bonnets (gas columns) to protect stem packing from freezing, ensuring operational reliability.
• Testing Protocols: Every unit undergoes strict inspection to ensure it handles thermal shock without seizing or leaking.

Triple Offset Butterfly Valves (TOV): The Standard for LNG Regasification

While the industry often looks to TOVs for regasification, we ensure that the entire isolation loop maintains zero-leakage performance using our API 6D certified portfolio. In high-pressure regasification lines where gas volume expands rapidly, reliable flow control equipment is non-negotiable.

• Critical Isolation: We supply robust Trunnion Mounted Ball Valves and Gate Valves that work in concert with regasification systems to provide absolute shut-off.
• Metal-to-Metal Sealing: Essential for handling the abrasive nature of high-velocity gas post-regasification.
• Fire Safe Compliance: All our isolation valves meet API 607 standards, ensuring safety even in the event of a terminal fire.

Marine Loading Arms: Quick Connect/Disconnect Safety Systems for Vessels

The transfer zone between the terminal and the vessel is the highest risk point in the LNG value chain. We provide the critical automatic shut-off valves and isolation units that integrate into marine loading systems to ensure safe, rapid disconnection during emergencies.

• Emergency Shutdown (ESD): Our actuated ball and gate valves are engineered for fast closure to support Safety Systems for Vessels.
• Subsea Control Compatibility: Our designs can be adapted for interface with subsea control systems and offshore platforms.
• Corrosion Resistance: Given the saline marine environment, our valves are coated and constructed from materials designed to resist saltwater corrosion while maintaining internal cryogenic compatibility.

HIPPS: The Ultimate Overpressure Protection Strategy

High-Integrity Pressure Protection Systems (HIPPS) vs. Relief Valves

We recognize that modern pipeline operations require smarter ways to handle pressure surges than traditional venting. High-Integrity Pressure Protection Systems (HIPPS) act as a barrier, isolating the source of overpressure rather than releasing valuable product into the atmosphere like a standard relief valve. This method is crucial for risk profile reduction and environmental compliance.

• Zero Emissions: Stops the flow instead of flaring gas.
• Asset Protection: Shields lower-rated downstream piping from high-pressure spikes.
• Cost Efficiency: Reduces the need to upgrade existing infrastructure to higher pressure ratings.

High-Speed Actuation: Achieving <2 Second Closure to Prevent Disaster

In a critical safety loop, reaction time is non-negotiable. We engineer our high-speed actuation packages to deliver closure times of less than two seconds when necessary. Our dedicated automation engineering team pairs high-torque pneumatic or hydraulic actuators with our robust valves to ensure immediate response during an upset condition.

• Rapid Response: Custom automation packages designed for specific timing requirements.
• Reliable Torque: Sized to close effectively against full differential pressure.
• Testing: Rigorous cycle testing performed at our facility to verify speed and reliability.

Integrating Logic Solvers and Interlocks for SIL 3 Compliance

The final element—the valve and actuator assembly—is the physical heart of any safety instrumented system. We supply flow control hardware that integrates seamlessly with third-party logic solvers to support SIL 3 compliance requirements.

• Fail-Safe Configuration: Systems designed to default to a safe position (open or closed) upon loss of power or signal.
• Partial Stroke Testing: Actuation packages capable of verifying movement without interrupting the process flow.
• Custom Interlocks: Mechanical locking devices installed to prevent unauthorized manual operation.

Critical Equipment: Valves, Actuators, and Instrumentation

Automatic Shut-Off Valves (ASUV): Fail-Safe Logic for Emergency Shutdown

We engineer our API 6D Trunnion Ball and Gate valves to serve as the backbone of your safety systems. In midstream applications, Automatic shut-off valves are the last line of defense. We integrate our valves with high-performance actuators to ensure immediate isolation when Flow control equipment detects an anomaly. By handling the assembly and testing in our manufacturing facility, we guarantee that the valve and logic system operate seamlessly together.

Actuation Choices: Gas-Over-Oil vs. Electro-Hydraulic Systems

Selecting the right power source is vital for reliability in remote or plant environments. We provide comprehensive actuation packages tailored to your specific site conditions:

• Gas-Over-Oil: Ideal for remote pipelines, utilizing line pressure for robust operation without external power.
• Electro-Hydraulic: Offers precision control for terminals where electricity is available.
• Pneumatic Actuation: A standard choice for processing facilities with available plant air.

Balance of Plant: Small-Bore Tubing, Manifolds, and Instrumentation Panels

The reliability of an automated valve package often depends on the quality of its accessories. When we deliver a control package, we ensure the Instrumentation panels and auxiliary components are built to withstand harsh industrial environments. We pay close attention to the Small-bore tubing and connections used in the control loop. By utilizing Leak-tight fittings and high-grade materials, we prevent fugitive emissions and pressure drops that could compromise the actuator’s response time. We deliver a fully integrated solution, ready for immediate installation.

The "Green" Pipeline: Methane Reduction & Fugitive Emissions

Low-E Packing Technology: Meeting ISO 15848 Standards

Fugitive emissions often occur at the valve stem, which is why standard packing just doesn’t cut it anymore. We utilize advanced Low-E (Low Emission) packing technologies designed to meet rigorous industry benchmarks like API 624 and ISO 15848.

• Tight Tolerances: Our machining process ensures the stem and bonnet interface is precise, reducing the gap where gas could escape.
• Certified Testing: We conduct rigorous in-house testing to verify seal integrity under fluctuating pressures.
• Material Selection: We use high-grade graphite and proprietary materials that maintain resilience even after thousands of cycles.

Leak Detection Systems (LDS): Real-Time Monitoring Points along the Pipeline

A robust leak detection strategy relies on the reliability of every component in the line. Our API 6D Trunnion Ball Valves and Gate Valves serve as critical monitoring points within the infrastructure. By ensuring a bubble-tight seal, we eliminate false positives in your LDS, allowing for accurate, real-time data analysis.

Electrification of Actuators: Removing Pneumatic Bleed from the Loop

Traditionally, pipelines relied heavily on pneumatic actuation that utilized the line gas itself, often resulting in intentional methane venting during operation. To support the “Green” pipeline initiative, we offer comprehensive factory-integrated actuation packages focused on electrification.

• Zero-Bleed Operations: Electric actuators eliminate the need to vent gas, significantly lowering the facility’s carbon footprint.
• Precision Control: Electric systems provide granular control over valve positioning compared to traditional hydraulic or pneumatic systems.

Safety Standards and Lifecycle Support

Navigating PHMSA Regulations and Safety Integrity Level (SIL)

We understand that compliance isn’t optional in the midstream sector. Our manufacturing processes are strictly aligned with API 6D and API 6A standards, ensuring our valves meet the rigorous demands of PHMSA regulations and international safety codes. By adhering to ISO 9001:2015 quality management systems and API 607 Fire Safe testing, we contribute directly to risk profile reduction across your infrastructure.

Remote Control Valves: Integrating with SCADA for Unmanned Operation

Modern pipelines rely heavily on process automation to manage flow without constant human presence. We specialize in providing remote control valves equipped with custom actuation packages installed and tested at our factory.

• Seamless Integration: Our actuated packages are designed to interface perfectly with your SCADA systems.
• Reliable Actuation: We fit pneumatic, electric, or hydraulic actuators to our Trunnion Ball and Gate valves to ensure precise control.
• Factory Testing: We verify the torque and cycle speeds before shipment, ensuring the valve responds instantly when your control room sends a command.

Retrofit & Modernization: Upgrading Aging Pipeline Infrastructure

Effective integrity management often requires replacing outdated components on a tight schedule. We support your modernization projects through our strategic inventory and agile production lines. Whether you need a replacement Slab Gate valve or a specialized Check valve, we can manufacture to fit your existing pipeline infrastructure and piping configurations. This capability allows us to minimize downtime and extend the lifecycle of your assets, offering a cost-effective alternative to rigid Tier 1 suppliers.

Frequently Asked Questions (FAQ)

What is the difference between an ESD valve and a standard SDV?

While both serve to stop flow, the distinction lies in criticality and speed. A standard Shutdown Valve (SDV) is used for routine process isolation. An Emergency Shutdown (ESD) valve is your safety net for critical failures. Our ESD packages are engineered for higher safety integrity levels, utilizing high-speed actuation to cut through full differential pressure instantly.

Why are Top-Entry Ball Valves preferred in LNG plants?

In LNG terminals and midstream facilities, downtime is expensive. We recommend Top-Entry Ball Valves for these applications primarily for their in-line maintenance capabilities. You can access the ball and seats directly from the top bonnet without cutting the valve out of the pipeline, significantly reducing the maintenance window in critical High-Integrity Flow Control loops.

How does a HIPPS system reduce flare usage?

Traditional safety systems use relief valves to vent excess gas to a flare stack during an overpressure event. A High-Integrity Pressure Protection System (HIPPS) takes a cleaner approach. Instead of venting, the HIPPS loop detects the pressure spike and triggers our fast-acting isolation valves to shut off the source immediately, achieving zero emissions and protecting downstream assets.

Ready to Optimize Your Pipeline Integrity?

Don't let long lead times delay your project commissioning. DELCO Valves combines global manufacturing efficiency with strict API 6D compliance to deliver high-performance flow control solutions when you need them.

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